Apparatus and Methods For Connecting Timber Flanges

ABSTRACT

A method and apparatus for constructing a single story or multistory building using timber as a major structural material. The apparatus includes a connector plate having a series of pins extending therefrom. In a building component, each pin engages with a relatively small diameter timber flange by way of an axial bore hole formed in each flange. In this way, the flanges form a timber structural member useful in the formation of a framework of a building structure. The plate of the connector provides a fastener for fastening to other similar connectors or to other building structures. Various combinations of connectors and building flanges may be used to construct a single story building, and furthermore may be used in the construction of a multistory building.

FIELD OF THE INVENTION

The present invention is directed to the field of building construction,and particularly the construction of multistorey buildings using timberas a major structural material.

BACKGROUND TO THE INVENTION

The stability of multistorey buildings is typically conferred usingsteel or reinforced concrete, or a combination of the two materials. Asteel frame alone may be used in low rise buildings. For medium risebuildings either concrete or braced steel cores are typically used. Forhigh rise buildings a concrete core may be used to facilitate theconstruction process. The core confers stability as steelwork is erectedabout the core. In some high rise buildings, an ‘exoskeleton’, may alsobe used to confer stability, this typically requiring substantialtemporary works as the final stability system is only complete after asignificant number of floors are erected.

The corrosion of steel as a component of reinforced concrete is a wellknown problem in building construction. Ideally, concrete providesadequate protection to the embedded steel by way of the protectivealkaline environment provided by fresh concrete to form a protectivecoating on the surface of the steel, which protects it from corrosion.However, over time pH declines slowly and the alkaline conditions arelost, leading to increased probability of steel corrosion. Maintenanceof an alkaline environment can be ensured by providing sufficient cementcontent, complete compaction and proper curing. However, these measuresare firstly difficult to realize in practice fully and secondly the sameare not found to be sufficient in hostile environments.

Corrosion is also a problem of structural steel beams used in buildingconstruction. Corrosion may be addressed by the use of a paint systemcomprising sequential coating application of paints or alternativelypaints applied over metallic coatings to form a ‘duplex’ coating system.Protective paint systems usually consist of primer, intermediate/buildcoats and finish coats. Metallic coatings may be used such as by theprocesses of hot-dip galvanizing and thermal spraying. Eventually, suchcoating will break down and expose the underlying structural steel tothe environment leading to corrosion.

Quite apart from the problems of corrosion, acceptable quality concreteor steel may not be available, or may not be available at an acceptablecost.

Taking into account environmental considerations, it is well known thatthe concrete industry is one of two largest producers of carbon dioxide,creating up to 5% of worldwide man-made emissions of this gas, of which50% is from the chemical process and 40% from burning fuel. Clearly, theproduction of steel is a highly energy-consuming process (mainly due tothe use of vast amounts of heat energy in smelting) and therefore asubstantial contributor to carbon dioxide production.

As an alternative to steel and concrete, timber has been used in theconstruction of multistorey buildings. However, timbers having highcross-sectional areas must be used to provide the load bearingcapacities and spans required. Such timbers are typically very expensivegiven the need to harvest the wood from the prime regions of very maturetrees.

More recently, engineered timbers such as laminated veneer lumber (LVL)and glue laminated timber have been used in building construction. Inproducing these products, layers of wood are glued (laminated) togetherwith heat, resin binder, and pressure to form a very strong structuralmember that can be produced in regular sizes and lengths. Whilegenerally effective, these wood products are expensive and therefore notuseable in many applications. Furthermore, there is significant energyinput required in production (mainly in heat energy) and also the use ofchemicals (such as adhesive and binder).

Engineered timbers must be produced by very precise manufacturingmethods, having rigorous QA and QC requirements. Accordingly, theseproducts are not widely available and may need to be transported longdistances to a building site. Where available, these products areexpensive and may not be cost-effective for many applications.

It is an aspect of the present invention to overcome or ameliorate aproblem of the prior art by providing materials and methods to constructa multistorey building deriving primary stability from neither steel norconcrete. It is a further aspect of the present invention to providealternative materials and methods for building construction.

The discussion of documents, acts, materials, devices, articles and thelike is included in this specification solely for the purpose ofproviding a context for the present invention. It is not suggested orrepresented that any or all of these matters formed part of the priorart base or were common general knowledge in the field relevant to thepresent invention as it existed before the priority date of each claimof this application.

SUMMARY OF THE INVENTION

In one aspect of the invention, but not necessarily the broadest aspect,the present invention provides a connector for collocating a group oftimber flanges, the connector comprising a main region, the main regionhaving extending therefrom a plurality of engaging members each of whichis configured to engage with a timber flange.

In one embodiment of the first aspect, the main region comprises meansfor fastening the connector to a substantially similar or identicalsecond connector.

In one embodiment of the first aspect, the main region comprises meansfor connecting the connector to a building structure.

In one embodiment of the first aspect, the main region comprises a firstsubstantially planar region and a second substantially planar region,the first and second planar regions forming an angle of about 90degrees, the first planar region comprising means for connecting theconnector to a substantially similar or identical second connector, andthe second planar region comprising means for connecting the connectorto a building structure.

In one embodiment of the first aspect, the means for connecting theconnector to a substantially similar or identical second connector orthe means for connecting the connector to a building structure is anaperture configured to accept a fastener.

In one embodiment of the first aspect, the main region consists of, orcomprises, a plate.

In one embodiment of the first aspect, the main region comprises asubstantially planar face, and the group of engaging members extendsubstantially orthogonal from the planar face.

In one embodiment of the first aspect, the engaging members are disposedin an ordered array with reference to each other.

In one embodiment of the first aspect, the engaging members form a row,or a series of rows.

In one embodiment of the first aspect, the engaging members form a gridarrangement.

In one embodiment of the first aspect, the engaging members form acircle with a central engaging member at the origin, or two or moreconcentric circles.

In one embodiment of the first aspect, each of the plurality of theengaging members extends at least about 1 cm, 2 cm, 3 cm, 4 cm, 5 cm, 6cm, 7 cm, 8 cm, 9 cm or 10 cm from the main region.

In one embodiment of the first aspect, each of the plurality of engagingmembers are substantially solid and have a cross sectional area greaterthan that of a 2 gauge nail.

In one embodiment of the first aspect, each of the plurality of engagingmembers are substantially solid and have a cross section area of atleast about 0.01 cm², 0.02 cm², 0.03 cm², 0.04 cm², 0.05 cm², 0.06 cm²,0.07 cm², 0.08 cm², 0.09 cm², 0.1 cm², 0.2 cm², 0.3 cm², 0.4 cm², 0.5cm², 0.6 cm², 0.7 cm², 0.8 cm², 0.9 cm², 1 cm², 2 cm², 3 cm², 4 cm², 5cm², 6 cm², 7 cm², 8 cm², 9 cm² or 10 cm².

In one embodiment of the first aspect, each of the plurality of engagingmembers is a substantially linear member.

In one embodiment of the first aspect, each of the plurality of engagingmembers have substantially identical morphology.

In one embodiment of the first aspect, the connector comprises at leastabout 4, 6, 8, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34 or 36engaging members.

In one embodiment of the first aspect, the main region consists of, orcomprises, a plate and each of the plurality of engaging members is adowel or pin extending from the plate.

In one embodiment of the first aspect, the connector is fabricated inwhole or in part of a metal.

In one embodiment of the first aspect, the metal is corrosion resistant,or is treated so as to be corrosion resistant.

In one embodiment of the first aspect, the connector comprises a supportmember extending from the main region in a direction generally away fromthe engaging members.

In one embodiment of the first aspect, the connector is configured toend join a first group of timber flanges to a second group of timberflanges, the connector comprising a main region, the main region havingextending therefrom a plurality of engaging members each of which isconfigured to engage with an axial bore of timber flange, the pluralityof engaging members comprising a first group and a second group, whereinthe first group extends in a first direction and the second groupextends in a second direction.

In one embodiment of the first aspect, the main region comprisesopposing first and second substantially planar faces, wherein the firstgroup of the engaging members extend substantially orthogonal to thefirst planar face and the second group of engaging members extendsubstantially orthogonal to the second planar face.

In one embodiment of the first aspect, the number of engaging members inthe first group is equal to the number of engaging members in the secondgroup.

In one embodiment of the first aspect, each of the plurality of engagingmembers have substantially identical morphology.

In one embodiment of the first aspect, the first and/or second group ofengaging members comprises about 4, 6, 8, 10, 12, 14, 16, 18, 20, 22,24, 26, 28, 30, 32, 34 or 36 engaging members.

In one embodiment of the first aspect, the first and second group ofengaging members are arranged substantially identically, and or havesubstantially identical morphology.

In a second aspect the present invention provides a building componentcomprising the connector according to any embodiment of the first aspectand a plurality of timber flanges, each of the timber flanges having anaxial bore into which is received an engaging member.

In one embodiment of the second aspect, a longitudinal surface of eachof the plurality of timber flanges contacts a longitudinal surface of atleast one other timber flange.

In one embodiment of the second aspect, each of the plurality of timberflanges is a pole.

In one embodiment of the second aspect, each of the plurality of timberflanges is a true round or a peeler core.

In one embodiment of the second aspect, the longitudinal surface isformed by removing a longitudinal segment of each of the contactingflanges so as to provide a substantially planar surface.

In one embodiment of the second aspect, the longitudinal surface isformed by removing a longitudinal segment of upper and/or lower timberflanges so as to provide a bearing surface and/or a mounting surfacerespectively.

In one embodiment of the second aspect, two contacting timber flangesare secured together with a fastener extending at an angle to the longaxes of the timber flanges.

In one embodiment of the second aspect, the building component comprisesa second connector according to any embodiment of the first aspect, afirst group of timber flanges collocated by the first connector and asecond group of time flanges collocated by the second connector, thefirst and group of timber flanges oriented end-to-end, the first andsecond connectors being fastened together so as to form a structurallyintegral unit.

In one embodiment of the second aspect, the building component comprisesa structural column, wherein the first and second connectors aredisposed on, and fixed to, the upper face of the column (or the columntop plate, where present) and the first connector is fastened to thesecond connector.

In one embodiment of the second aspect, the building component comprisesthe connector of the first aspect having a support member as a thirdconnector, the support member of the third connector interposed betweenthe first and second connector, and the first connector is connected tothe second connector (optionally by way of the support member of thethird connector).

In one embodiment of the second aspect, the building component ofcomprises a third group of timber flanges collocated by the thirdconnector.

In one embodiment of the second aspect, the building component comprisesthe connector according to any embodiment of the first aspect as afourth connector,

In one embodiment of the second aspect, the building component comprisesa fourth group of timber flanges collocated by the fourth connector.

In one embodiment of the second aspect, the fourth connector is fastenedto the first and second connectors.

In one embodiment of the second aspect, the first and second group oftimber flanges are configured as joists, the third group of timberflanges is configured as column of a (n+1) storey of a building, and thefourth group of timber flanges is configured as column of a (n) storeyof the building.

In a third aspect, the present invention provides a method ofconstructing a multistorey building, the method comprising the steps ofproviding the building component according to any embodiment of thesecond aspect or a connector of the first aspect.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1A is a diagram in perspective view of paired preferred connectorsof the present invention, each collocating a series of four preferredstacked timber flanges.

FIG. 1B is an end view of the paired connectors shown in FIG. 1A

FIG. 2A is a diagram in lateral view of a preferred building componentof the present invention comprising an upper vertical beam, a lowervertical beam and two horizontal beams. This embodiment is useful sincethe space disposed above the horizontal beams allows for the pouring ofa concrete floor thereon.

FIG. 2B is a plan view of the building component shown in FIG. 2A.

FIG. 3 is a diagram in lateral view of a preferred building component ofthe present invention comprising an upper vertical beam, a lowervertical beam and two horizontal beams. Flooring may be laid on top ofthe horizontal beams.

FIG. 4 is a diagram in plan view of a preferred building structure ofthe present invention which may be used at the corner of a building,

FIG. 5A is a preferred modular building structure of the presentinvention. The modular structure may be repeated as often as requiredaccording to the floor space needed.

FIG. 5B shows a similar modular building structure to that shown in FIG.5A, although constructed as two half modules which are bolted togetheralong the median line.

FIG. 5C shows is a diagram in later view showing the formation of a beamhaving a ledge, the ledge support the end of a joist. Such structuresmay be useful in the modular embodiments of the invention shown in FIG.5A or 5B.

FIG. 5D is a diagram in perspective view of connector plates used toend-join two sets of collocated timber flanges. Such means may be usedwhere the flanges must span relatively long distances.

FIG. 6 is a diagram in perspective view showing a preferred buildingstructure of the present invention configured to join four horizontalbeams, an upper column and a lower column. For clarity, not allcomponents of the structure are shown in the diagram.

FIG. 7 is a diagram in perspective view showing a connector configuredto join two of more L-shaped connectors of the type shown in FIG. 1A.

DETAILED DESCRIPTION OF THE INVENTION

Reference throughout this specification to “one embodiment” or “anembodiment” means that a particular feature, structure or characteristicdescribed in connection with the embodiment is included in at least oneembodiment of the present invention. Thus, appearances of the phrases“in one embodiment” or “in an embodiment” in various places throughoutthis specification are not necessarily all referring to the sameembodiment, but may. Furthermore, the particular features, structures orcharacteristics may be combined in any suitable manner, as would beapparent to one of ordinary skill in the art from this disclosure, inone or more embodiments.

Similarly it should be appreciated that the description of exemplaryembodiments of the invention, various features of the invention aresometimes grouped together in a single embodiment, figure, ordescription thereof for the purpose of streamlining the disclosure andaiding in the understanding of one or more of the various inventiveaspects. This method of disclosure, however, is not to be interpreted asreflecting an intention that the claimed invention requires morefeatures than are expressly recited in each claim. Rather, as thefollowing claims reflect, inventive aspects lie in less than allfeatures of a single foregoing disclosed embodiment. Thus, the claimsfollowing the Detailed Description are hereby expressly incorporatedinto this Detailed Description, with each claim standing on its own as aseparate embodiment of this invention.

Furthermore, while some embodiments described herein include some butnot other features included in other embodiments, combinations offeatures of different embodiments are meant to be within the scope ofthe invention, and from different embodiments, as would be understood bythose in the art.

In the claims below and the description herein, any one of the terms“comprising”, “comprised of” or “which comprises” is an open term thatmeans including at least the elements/features that follow, but notexcluding others. Thus, the term comprising, when used in the claims,should not be interpreted as being limitative to the means or elementsor steps listed thereafter. For example, the scope of the expression amethod comprising step A and step B should not be limited to methodsconsisting only of methods A and B. Any one of the terms “including” or“which includes” or “that includes” as used herein is also an open termthat also means including at least the elements/features that follow theterm, but not excluding others. Thus, “including” is synonymous with andmeans “comprising”.

Furthermore, it is not represented that all embodiments display alladvantages of the invention, although some may. Some embodiments maydisplay only one or several of the advantages.

Some embodiments may display none of the advantages referred to herein.

The present invention is predicated at least in part on Applicant'sproposal that relatively small diameter timbers may be collocatedtogether to form a composite structural beam using a connector asdescribed herein. The connector comprises a number of engaging members,each of which extends into a small diameter timber flange therebycollocating the timber flanges into a composite structural member.Accordingly, in a first aspect the present invention provides aconnector for collocating a group of timber flanges, the connectorcomprising a main region, the main region having extending therefrom aplurality of engaging members each of which is configured to engage witha timber flange.

As will be described more fully infra, the present connectors can takemany forms and may be used (in combination with timber flanges) toprovide column structures, beam structure, and combination column/beamstructures all of which make use of timber such as timber rounds andsmall diameter peeler cores. Furthermore, the present connectors allowfor timber to be used in the construction of multistorey buildings. Thepresent invention therefore represents a significant departure fromprior art construction and hardware which typically rely on largecross-section sawn timber or steel members for creating the load bearingstructures in a building.

The composite structural members that may be produced using the presentconnectors can be used as a column, a beam, a half-beam, a bearer, ajoist, a brace, a truss or any other structural member of a building. Aswill be more fully discussed infra, the connectors may be used also tojoin composite structural members both as a means for end joining andfor making right-angled joins between a column and a beam, for example,where the column and beam are both collocated timber flanges.

These arrangements allow for the construction of buildings of at leastseveral storeys having a frame work predominantly of timber. In someembodiments of the invention, the building may be constructed fromtimber rounds, and even smaller diameter timbers such as peeler cores

The present connector is typically formed having main planar region(being a plate in one embodiment), and having engaging members extendingat 90 degrees therefrom. The engaging members may be pins or bars whichare generally disposed in a regular manner so as to be insertable intoan axial bore of each timber flange that is collocated by the connector.The combination of plate and engaging members acts to prevent the timberflanges from acting individually in so far as one flange may not move(axially, radially or rotationally) with reference to another. Thecollocated timber flanges may therefore act similar to a unitarystructural member with regard to the transference of load therethrough.Thus, the collocated flanges may be used to replace single largecross-section timbers, and even steel members in building construction.

Unless the contrary is stated, where building structural members arerecited herein (such as “column” or “beam”) it is to be taken that suchstructural members are formed by a number of timber flanges collocatedby connection to a connector or the present invention. Typically, twoconnectors will be used: one at each end of the flanges. The number offlanges collocated together to form a structural member will depend onthe load expected in use. Broadly speaking, an increased load willrequire an increased number of flanges, or flanges having an increasedcross-sectional area. The flanges may be disposed linearly (i.e. oneatop the other, comprising 2, 3, 4, 5, 6, 7, 8, 9 or 10 flanges), or ina grid formation (for example having 2, 3, 4, or 5 rows; with 2, 3, 4 or5 columns). In some embodiments the grid formation is a square (such as2 rows×2 columns), however other formations are contemplated (such as 4rows×1 column, or 3 rows by two columns).

Whilst it is the primary role of the engaging members to locate a fixthe positions of the flange ends and prevent each flange from actingindividually, a secondary role may be to prevent crushing of the woodfibres in the flange ends. The engaging members may transfer at leadsome of any downward load imparted on the connector to regions deeper inthe flange.

In one embodiment, the engaging member may be configured to extend atleast about 1 cm, 2 cm, 3 cm, 4 cm, 5 cm, 6 cm, 7 cm, 8 cm, 9 cm or 10cm into the flange. To resist deformation forces occasioned on theengaging member (for example, by compression due to overlying structuresor lateral forces) the engaging member may be configured to have aminimal cross-sectional area having regard to the expected level ofdeformation force that may be applied in a given application. A memberhaving a cross sectional area greater than that of a 2 gauge nail isuseful in many applications, with preferred forms being similar to arebar (high yield rebar, high tensile rebar or mild steel rebar) havingdiameters of at least about 5 mm, 6 mm, 8 mm, 10 mm, 12 mm, 16 mm, 20mm, 24 mm, 25 mm, 28 mm, 32 mm, 40 mm or 50 mm.

The engaging members are generally elongate and linear and configured toinsert into a borehole made centrally and axially into the end of theflange. The dimensions of the engaging member and flange may beconfigured such that a pressure fit is provided. Alternatively somespace may be left between the two components to allow for the use of anadhesive. In any event, the growth rings of the flange (which may beconcentric with the engaging member) may act to resist deformation ofthe engaging member and to spread load evenly throughout the flanges andconnector. Generally the engaging members are identical, however thisfeature is not considered essential to all forms of the invention.

In some embodiments, the engaging member may have profiles which are notstrictly pin-shaped or bar-shaped. A member may be wedge-shaped, conicalor pyramidal for example.

The main region of the connector and the engaging members is typicallyfabricated from a deformation-resistant material such as steel, or ahigh strength polymer. In many embodiments, the main portion of theconnector (typically being a plate) and the engaging members (typicallyin the form of pins) are both fabricated from steel. The plate may beseparately fabricated and the pins attached by welding (or equivalentmeans of fixation), or the entire connector may be formed or moulded asa unitary product. In other embodiments, holes are formed in a plate andthe engaging members are threaded and screwed through the plate to as toextend outwardly from the other side. Given the benefit of the presentspecification, the skilled person is amply enabled to conceive of othersuitable methods for forming an engaging member on the main region ofthe connector. In one embodiment, the main region is a plate and theengaging members extend from the plate. It is not necessary for the mainregion to be a continuous structure, with some embodiments havingcut-outs or other discontinuities therein.

The main region of the connector may or may not be configured to extendbeyond the periphery of the collocated flanges in any or all directions.In some applications (and often for fire safety reasons) the main regionis smaller in cross-sectional area than the region described by theperiphery of the collocated flanges. This allows for horizontal sheetingto be recessed into and above the end timber area equally around themain region to abut the sides thereof. The concrete floor or sheeting onthe next (upper) storey can be recessed into any under any timber endgrain area thereby concealing or rebating the connector man region andprotecting both connector and timber ends from direct heat or flame. Apotential disadvantage of this embodiment is that the amount of loadthat can be assumed by the plate is reduced, however this may beovercome by the use of more or larger cross-sectional area flanges.

A composite column comprising a connector of the present invention, asconnected to may act in the a building application as a component of asecondary directed load sharing system which depends at least to someextent on the flat end bearing capacity of the end fibres of theplurality of timber flanges collocated together (at the top and bottom),and in particular to the fibres ability to bear loads in compressionfrom a present connector which is already bearing a load from asimilarly collocated group of flanges above.

The connector may have engaging members extending in two directions fromthe main region. In one embodiment, the engaging members extend fromopposed sides of the main region. Such embodiments are useful in endjoining a first group of flanges to a second group of flanges.

In another embodiment, the connector is configured to fasten to anotheridentical or similarly functioning connector. In this way, a firstconnector may be used to collocate a first set of timber flanges, asecond connector may be used to collocate a second set of timberflanges, and the first connector is fastened to the second connector soas to form an indirect structural connection between the first andsecond groups of flanges.

Alternatively, the connector may be configured to fasten to a building,or a part of building during construction thereof. For example, theconnector may be configured to connect to a prior art building componentsuch as a column, a beam, a bearer, a joist, a truss or any other framemember of a building. Configuration may also be provided to connect tonon-timber building components such as a steel frame component, aconcrete component, or a masonry component. As a further alternative,configuration may be provided to connect to building hardware such as abracket, a brace, a plate a cap or similar contrivance. As a furtheroption, the connector may be configured to fasten to a structural memberformed by the collocation of a number of timber flanges with a connectorof the present invention.

In a form configured so as to facilitate fastening, the connector maycomprise one or more apertures dimensioned to receive a bolt or similarfastener. A bolt may extend through the apertures of two connectors witha nut being used to make the fastening semi-permanent. As analternative, a clamping mechanism may be used to fasten a firstconnector to a second connector or other building component. In anotherversion, threaded pins may be used to fasten the present connector toanother connector or other building component. Given the benefit of thepresent specification, the skilled person is enabled to conceive ofother fastening means and configure the connector accordingly.

The engaging members may be configured to be driven directly into theflanges in a manner similar to a nail such that the act of driving inthe engagement member forms a borehole in the flange. In somecircumstances, this may lead to splitting of the flanges in which casealternative means are used. Preferably, each of the engaging members isconfigured as a pin configured to be inserted into a pre-formed bore ofthe flange. An adhesive may be injected into the bore before insertionof the engaging member so as to provide for a more dependable union.

Typically, the flanges are of equal length, and a connector is appliedto both ends of the flanges. Thus, the flanges are bound together atboth ends and the flanges are substantially incapable of radial movementrelative to each other or axial movement relative to each other.

As discussed supra, the present connector has advantage in so far asmultiple wood flanges of relatively small diameter may be collocated toform a unified composite structural member. Suitable flanges includetimber rounds. Timber rounds are described in Section 6 of AustralianStandard 1720, and are typically produced from softwood trees growncommercially as renewable forest plantation timber. These timbers aretypically fast growing, easily harvested, and have a low natural defectrate.

Various species of timber are suitable to form the true rounds,particularly those types of species that tend to have a relativelyconstant diameter for a considerable portion of their length to minimisewaste during the trimming and circularising processes. Plantation pinematerials, such as slashpine or Carribaea hybrids, tend to form suitabletrue rounds. Other materials that might be considered include Douglasfir, and various eucalypt species.

True rounds are particularly strong since the natural strength of thetimber fibres is not disrupted by sawing or other treatment. Theintegrity of the round is maintained, and the trimming process requiredto circularise the round does not greatly affect the overall strength ofthe round. The natural characteristics of timber are that the centralcore or pith of the round is relatively soft and has low structuralstrength. The periphery of the timber, on the other hand, is much harderand the timber fibres are able to carry a high tensile load. Also, thishard outer layer is more resistant to water absorption and attack byinsects, and thus by keeping the outer circumference of the timberlargely intact in the process of preparing a true round, the structuralintegrity of the timber is maintained

The rounds in some forms of the invention do not strictly conform toAustralian Standard 1720, and may be of a smaller diameter such that theStandard is not satisfied. However, by the fastening of at least threerounds together a required load bearing capacity may be neverthelessattained.

In some embodiments, the timber flanges are “peeler cores”. As isunderstood by the skilled person, a peeler core is a round pressuretreated post. A peeler core has been turned in a milling machine to thepoint that substantially all the soft wood has been removed (for plywoodmanufacturing), leaving the hardwood core which is typically dense andinflexible. The milling process peels off the bark, cambium layer,sapwood, and even some of the heartwood to make veneer panels. Thisleaves no sapwood on the post.

The hardwood core of a peeler core does not absorb the pressuretreatment and preservatives as well as the softwood resulting in aninferior post that will typically not last as long as a post withtreated softwood on the exterior.

Applicant has discovered an economically and technically viable use forpeeler cores in that the cores may be used in a composite timber productsuch as that disclosed herein. The use of multiple peeler cores (andeven those with a diameter down to about 70, 60, 50 or 40 mm) canproduce a member which is useful in construction and yet is highlycost-effective. Peeler cores are often considered a waste product offorestry, having little value in the market. In one embodiment, thepresent invention is directed to timber structural members that arecomprised of peeler cores only in combination with a present connector.

Given the low diameters of peeler cores, it will be appreciated that agreater number of rounds may be required to achieve any desiredstructural property. For example, while a structural member composedonly of larger diameter rounds may only require 2 or 3 rounds, the useof peeler cores may require 4, 5, 6, 7 or 8 cores to achieve a usefulresult.

Typically, the flanges and connector are configured so as to ensure thatthe surface of each flanges makes contact with all neighbouring flanges.Thus, the diameter of the flanges and the spacing of the engagingmembers may be configured so as to ensure flange-to-flange contact. Aswill be appreciated, the diameters of timber rounds can be variable andthe spacing of engaging members is generally fixed. Accordingly, someembodiments of the invention provide for opposing longitudinal segmentsto be removed (by a chamfering process) from each flange so as toprovide opposing substantially planar surfaces which can act as acontact interface between flanges.

The amount of wood removed from a flange may be varied from flange toflange so as to provide a fixed distance between the flange centre andsubstantially planar surface. Thus, when two so-formed flanges arestacked on their long axes, the centre-to-centre distance is fixed. Thefixed distance is concordant with the distance between the engagingmembers of the connector and the so-formed composite structural memberis therefore assembled easily and with the avoidance of unforeseenforces acting on any of the flanges or engaging members that may becaused by poorly fitting components.

In some embodiments, the flanges are laminated together by an adhesivedisposed between the regions of contact between two flanges. In additionor alternatively, the flanges have fasteners extending therethrough, andgenerally across the long axis. For example, the fasteners may be steelrods inserted into bore holes made at alternating acute and obtuseangles to form a repeating V-pattern along the length of the flanges.This arrangement of fasteners provides a trussing effect to affordgreater resistance of the composite timber member to bending, and istherefore particularly useful where the flanges are used to form acomposite floor joist or similar. The flanges may be laminated togetheraccording to any of the various means disclosed in any of the followinginternational patent specifications, the contents of which are hereinincorporated by reference: WO/2015/176125, WO/2015/031957, andWO/2010/057243, WO/2009/094696, WO/2016/086275, Australian provisionalpatent application 2016902472 (filed 23 Jun. 2016).

In one embodiment, the main region of the connector has a support memberextending therefrom and generally in the direction opposite to that ofthe engaging members. Preferably, the main region is a plate disposedhorizontally, the engaging members extending upwardly and verticallyfrom the main region plate, the support member being a plate extendinggenerally downwardly from the centre of the main region plate. Thismodified version of the connector allows for the collation of group offlanges into an upwardly extending column, with the column beingsupported above a surface by the vertical plate support member.

In another embodiment, the connector is configured such that the mainregion is a plate that forms an angle (typically an angle of about 90degrees) such that a horizontal portion of the plate is (in use)disposed upon an underlying structure, the surface acting to supportand/or stabilise the vertically extending portion of the main region,the vertically extending portion having the engaging members extendinghorizontally therefrom. The horizontal portion may be configured tofasten to the underlying structure, and may have for example aperturesallowing for a fastener (such as a bolt or a screw) to pass through andextend into the underlying structure.

This combination of connectors having (i) right-angled main regions and(ii) support regions can be used to unify an upwardly extending column,a downwardly extending column, a beam extending horizontally to the leftand a beam extending horizontally to the right. By way of construction,the downwardly extending column is installed in place firstly with themain region plate collating the flanges which comprise the downwardlyextending column being set horizontally. The beams extending left andright horizontally are then mounted on the horizontal plate of theupwardly extending beam with the horizontally extending portions of theplates of each connector of each beam being mounted on and bolted to theunderlying plate. A space is left between the vertically extendingportions of the plates of each connector of each beam. The function ofthis space is to snugly accept the vertical plate support member of theconnector of the upwardly extending column. Bolts extend through (i) thevertical plates of the connectors of the beams and (ii) the verticalplate support member sandwiched between the aforementioned verticalplates. By this arrangement, a rigid unification of all components isprovided.

The present invention may comprise the combination of a number offlanges with a connector to form a structural column capable ofresisting compressive forces expected in building construction. In someembodiments, a connector is present on one of both ends of the flanges.In any event, where a downwardly acting force bears on an upwardlypresented face of the connector, the connect acts to transfer the forcedownwardly and into the underlying collocated flanges.

In other embodiments one or more connectors are used to join two groupsof flanges end-to-end so as to provide an extended length column.Without wishing to be limited by theory in any way, it is believed thatwhere the connector forms end-grain connections between an upper groupof collocated flanges and a lower group of collocated flanges so as toform an extended height column, the ends of the upper flanges transfersthe vertical load component through the connector and onto the ends ofthe lower flanges. The engagement pins engage the flanges (both upperand lower) and provide composite action in the nodal zone. For any givenbuilding application, and according to any relevant building code withreference to the final load to be assumed by the column, it will bepossible to determine the number of flanges and the cross-sectional areaof each flange so as to satisfy the application.

A present connector may be used in the construction of a multistoreybuilding. For example, a connector may be disposed at the interfacebetween two floors of the building such that the lower group ofcollocated flanges together define a beam traversing the floor toceiling of the first storey, and the lower group of collocated flangestogether define a beam traversing the floor to ceiling of the secondstorey. This arrangement can be repeated such so as to provide a thirdstorey, fourth storey, fifth storey etc. In applications for multistoreybuildings, it may be necessary to use flanges having a highercross-sectional area (or more flanges in total) as columns on the lowerstoreys of the building so as to support the vertical load imparted bymultiple upper storeys of the building.

Typically, in use the flanges are of equivalent length and arecollocated at both ends with a connector of the present invention. Thecollocation of flanges at both ends with connectors of the presentinvention prevents independent behaviour of flanges across the entirelength of the collocated flanges. This prevents buckling or warping ofthe flanges when placed under load by minimizing any moment bias in anygiven lateral direction perpendicular to the collocated flanges.

Much of the load may be orientated along the centroid of the column,thereby minimising or lessening the tendency of the flanges to buckle byvirtue of either unstable moment bias due to inherent eccentricity ofloading to the centroid, imperfections in timber cross-section,non-uniformity of timber material and the like. To minimise the prospectfor buckling, flanges having a symmetrical shape are preferred, andmoreover the regular disposition of flanges into a defined group ormatrix is preferred. Furthermore, flanges should preferably make contactwith other flanges as far as possible along their lengths so as toprovide a more highly stabilised structural member.

In order to further minimise column failure by buckling the flanges maybe optionally connected at one or more points such as by extending aretaining band about the circumference of the collocated flanges, and/orby an adhesive disposed at point of contact between two flanges, and/orby insertions of fasteners (such as steel dowels, optionally inserted alalternative angles along the flanges) through two or more flanges. Inaddition or alternatively to these measures, the flanges may be modifiedto increase the flange-to-flange contact area. For example, roundflanges may be chamfered along their length such that each flange has alarge contact surface suitable for contacting a similarly formed chamferon an adjacent flange. Methods of chamfering and laminating flanges arediscussed in Applicant prior published patent document WO/2015/176125,WO/2015/031957, and WO/2010/057243, WO/2009/094696, WO/2016/086275,Australian provisional patent application 2016902472 (filed 23 Jun.2016), the contents of which are incorporated herein by reference.

The present connectors may be used as a means for connection ofcollocated flanges, each group of collocated flanges extending outwardlyin 2, 3, 4 or 4 directions. Typically, an angle of substantially 90degrees or 180 degrees exists between any two flange collocations. Wheretwo flange collocations are concerned the connector and flangecollocations may form a linear shape (the connector being disposedbetween the two groups of flanges which are coaxial). Alternatively, thetwo collocated flanges may form an L-shape with the connector disposedat the angle of the L. Where three flange collocations are concerned,the flanges may form a T-shape with the connector disposed at theintersection of the T. Where four flange collocations are concerned, acruciform structure may result with the connector being located at thecentre of the cross.

Such combinations of connector and flange collocations is that aninter-storey cavity space between floor levels for housing can becreated. Collocated flanges which function as beams can be connectedbefore or at the same time that the next level of columns are installedfor an overlying storey such that a complete storey can be completedbefore commencing construction of the next. The zone provided can beused as a cavity into which services (such as air conditioning conduit,water, electrical cabling and the like) can be disposed. It is furtherproposed that this method of construction is more cost-effective adrequires shorter periods of time for which workers must operate atheights.

In another embodiment of combination connector/flange collocations,there is provided the combination of an upper connector plate (havingengaging pins extending upwardly therefrom) which bolts directly to anopposing mirror image lower connector plate (having engaging pinsextending downwardly therefrom) with the plates having means forlaterally joining one or more horizontal beams (each of the beams beingcollocated flanges). Such means may comprise a plate having laterallyextending engaging members. The plate may be bolted verticallydownwardly to the lower connecting plate.

The present invention may provide for rapid methods for constructingpre-formed panels on the ground of the building site or in a dedicatedfactory environment. The panels may be comprised of joists consisting oftwo half-beam bearers with a plurality of cross-joists are 450 to 600 mmcentres. The panels are lowered onto the top corners of 4 columns withonly the connector plates (previously engaged therewith) and the cornerconnections secured. When another panel is lowered the two side-by-sidehalf-beams are simply bolted together to form a whole beam. Theresultant grids can be quickly sheeted with timber flooring, forexample, or prepared for a slab as described infra.

Such panels or grids may comprise at least two joists acting a half-beambearers (say, 5 members high) cross joined by a plurality of similarjoists (say, 4 members high) at suitable spacing of between say 45 0 mmto 600 mm to form a 4.8 m×6 m grid or a 6 m×6 m grid for example. Thejoists may joined in the same plane and the joists ends may becollocated by a present connector, I which case the engaging members maybe wither Y bar or threaded bar. In addition the ends may be radiallycut so as to engage the rounded sides of the joists and be end boltedthrough the bearer joists in a non-moment bolted connection or belaminated on site in the case of a Y bar end connection.

A further advantage of the present connectors and collocated flanges isthat a composite concrete-to-timber slab may be poured without the needthe screw in numerous shear connectors into the tops of the joists andbearers. This is achieved in-factory be extending the rebar engagingmembers up above the joists and bearers. The bottom formwork or plylayer is designed to be recessed into the joists and bearers such thatthe tops of both are level. This can be safely achieved with sheets thatare fitted between joists from below, say of 400 mm to remain level withthe joist tops at 450 mm spacings. When the slab is poured with itsmultiple opposite-facing shear connectors the concrete slab becomesessentially composite with the timber and therefore unlikely toseparate.

Before the slab is poured, pods or anchors may be strategicallypositioned around the column or grid edges and running down to the thirdor fourth bearer or joist member to create further shear resistance forthe slab. This arrangement may be used at the corners of a building.

In some embodiments, the rapid installation methods of the presentinvention involve the use of any one or more of the following.

(i) Joists, which are in many embodiments collocated flanges. Theflanges are collocated by each of the flanges having an axial bore holeinto which inserts an engaging member (which may be a Y bar or athreaded bar). The ends of the joists may have ends which are radiallycut so as to engage the rounded sides of adjacent rounded structuressuch beams formed from timber rounds which act as bearers. In someembodiments, the beams to which the joists are configured to attach takethe form of half beam bearers as further described.(ii) Half beam bearers have the engaging members of the connector gluedinto the joist ends to form a half-beam bearer. The connectors arefurther attached to column collector plates by bolting down onto topconnector plates on site.(iii) Full beams are two half-beam bearers cross bolted or laminatedtogether to form a full beam. These can be used as cross beams betweencolumns where required.(iv) Top connector plates which are configured to be embedded (via theengaging members) and laminated into the tops of columns, so as tocollocate the individual flanges to form a column. The top connectorplate may be welded with two vertical plates in the centre configured toreceive and sandwich therebetween the downward facing flange of a columnabove which is through bolted together as well as to receive and supporta connector plate from up to four directions by bolting down through theplate. To avoid nuts or boltheads on the bottom, these may just be boltthreads extending upwardly from the top of the connector plates to screwthe nuts down onto.(v) Bottom connector plates having a welded flange vertical to theconnector plate on the opposite side of the engaging members. A columnsin embedded onto the engaging members. The connector plate and columncan be lowered into position onsite for through-bolting to otherconnector plates.(vi) Corner connector plates for corners of a building. These may have aflange plate running the same as for a normal connection or with thevertical flange plate at 45 degrees in either orientation or thevertical flange plate in the shape of a cross or just as a half-cross asa box section.

A preferred method of building is as follows. Four columns are loweredinto place firstly. Each column is a set of flanges collocated with aconnector plate. Grid-like building modules (each comprised ofintersecting joists and beams) are lowered down onto the connector plateand between the corners of the four column tops. From an under-platformor scaffold, workers secure connector plates with nuts and washers. Allother half-beam bearers and full beams are secured in this way.

The grids are then sheeted by passing appropriately-sized (say 400mm×2400 mm) ply sheet up through the spaces between joists and allowingthem to rest in preformed rebates. From above, concrete is poured ontothe ply to form a slab floor.

New columns are then lowered into the connection zone such that thevertical portion of the connector plate is sandwiched between theconnector plates at the top of the underlying column and bolt through tofix.

This basic method may be repeated so as to form a multistorey buildingframework.

The present invention will be more fully described by reference to thefollowing non-limiting preferred embodiments.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Reference is made to FIG. 1 which shows a perspective view of pairedconnectors (each connector marked as 10) of the present invention havinga main region, being a vertical plate 12 in this embodiment, the plate12 having extending at a right angles thereform a series of cylindricalpins 14 each of which is an engaging member configured to be received byan axial bore (not shown) made in each of a series of chamfered timberflanges 16. In this embodiment each connector 10 has a stacked series offour flanges 16. It will be noted that each of the flanges 16 abut eachother at the interface between the chamfered surfaces 17 so as toprevent any free play or rotation. Minor chamfering is applied also tothe inside surfaces 19 of the flanges 16 for the same reason. Thechamfered inside surfaces of the flanges are more clearly shown at FIG.6.

The plate 12 has a first series of bolt holes (not shown) into which ofeach a bolt 18 inserts to allow for fastening of the connector 10 to asecond identical connector set behind (not shown in this drawing), suchthat the plates of the two connectors are parallel and the pins for thefirst connecter extend in the opposite direction to those of the firstconnector. In other embodiments, the bolt ends may insert into anothertype of connector or any other building structure.

The plate 12 has a lower horizontal extension 20 extending at rightangles therefrom to form an L-shaped bracket. This lower extension 20functions so as to support the bottom flange 16A, but also to providemeans to fasten the connector 10 to an underlying connector (not shownin this drawing) or to an underlying building structure (not shown inthis drawing). In particular the lower extension 20 comprises a secondseries of bolt holes (not shown) through which a second series of bolts22 which facilitate such fastening to another connector or structure. Itwill be understood that it is not necessary for the connector to havebolt holes passing through both the vertical plate and the horizontalplate, although in this embodiment both are provided. It is to befurther understood that it is not necessary for the connectors to bepaired as shown in this drawing. In some embodiments a single connectormay be used, optionally with bolt holes disposed lateral to both sidesof the flanges 16.

The flanges 16 in the foreground are collocated by the connector in theforeground, with the flanges 16 in the background being collocated bythe connector in the background.

The connectors 10 are shown in end-on view in FIG. 2, whereby the minorchamfering on the inside abutting surfaces 19 of the flanges is moreclearly shown. In some applications, it will be preferable for theportions of the plate 20 that sit immediately below the flanges 16A tobe removed such that the flanges 16A are able to directly contact anunderlying support surface. In this way, the overall height profile ofthe combination of the connector 10 with flanges 16 is lowered.

Typically, the areas of plate 20 lateral to the flanges 16A remains as ameans for accepting the bolts 22.

Use of the paired connectors 10 in a first application is shown in FIG.2A (lateral view) and FIG. 2B (top view). In FIG. 2A the second of thepaired connectors 10 is disposed immediately behind the first (forwardmost, as drawn) connector and is therefore obscured.

As shown most clearly in FIG. 2A, there is shown a cruciform buildingstructure providing a vertical column and horizontal beam arrangement.This arrangement structurally connects an upper column 100, a lowercolumn 200, a left lateral beam 300 and a right lateral beam 400. Eachof the columns 100, 200 and beams 300, 400 are comprised of chamferedtimber flanges 16 as those shown in FIG. 1. The cruciform buildingstructure comprises L-shaped connectors 500, 510 which are disposedback-to-back in a mirror-image arrangement.

Each connector 500, 510 comprises a series of pins 14 each of whichengages with a flange 14 by way of an axial borehole (not shown) in theflange end. Each connector has a series of vertical bolt holes andhorizontal bolt holes to accept a series of bolts. The vertical boltholes of each connector 500, 510 are aligned so as to be fastenabletogether by horizontal bolts 18.

Together the flanges 16 collocated by the connector 500 form the lefthand laterally extending beam 300, and the flanges 16 collocated by theconnector 510 form the right hand laterally extending beam 400.

As is shown clearly in the plan view of FIG. 2B, the connector 500 has apaired connector 502 set adjacently thereto. In addition, the connector510 has a paired connector 512 set adjacently thereto.

A third connector 520 comprises a horizontal plate 522 from which aseries of pins 14 each of which extend so as to engage an axial bore(not shown) in each of the upper column 100 flanges 16. Together theflanges 16 collocated by the connector 510 form the upper column 100.Extending downwardly from the horizontal plate 522 is a vertical plate524 configured to snugly fit between the vertical plates of theconnectors 500, 510. The vertical plate 524 comprises bolt holes (notshown) positioned to accept the horizontal bolts 18.

A fourth connector 530 comprises a horizontal plate from which a seriesof pins 14 extend vertically and downwardly therefrom. Each of the pins14 engage with an axial borehole (not shown) in each flange 16. Togetherthe flanges 16 collocated by the connector 530 form the lower column200. The horizontal plate 532 comprises a series of bolt holespositioned so as to align with the bolt holes of the horizontal plate ofconnector 500 and connector 510.

The flanges 16 which form the columns 100 and 200 are chamfered in asimilar manner to the flanges shown in FIGS. 1A and 2B

In the embodiment of FIG. 2A, the vertical flanges 16 of column 100 forma column of an upper storey of a building, while the column 200 formsthe column of an immediately lower storey of the building. The flanges16 are disposed in a 4×4 matrix, and accordingly the pins 14 extendingfrom the horizontal plates 522 and 532 are disposed in a 4×4 matrix suchthat each pin engages with an axial borehole of its corresponding flange16.

In the course of construction, the connectors 500, 510 and 530 (eachwith its respective column or beam already engaged) are bolted together.The third connector (with its column attached) is lowered into the spacebetween the horizontal plates of connectors 500 and 510. The connectors500 and 510 are then bolted together.

Ply may be laid on top of the upper flanges 16 of beams 300, 400 andconcrete poured thereon.

FIG. 2B shows a plan view of the cruciform building structure of FIG.2A.

Reference is now made to FIG. 3 which shows an alternative cruciformbuilding structure which is similar to that of FIGS. 2A and 2B, the maindifference being that the upper vertical column 100 is disposed betweenthe connectors 500 and 510 with there being no requirement for avertical plate (524 of FIG. 2A) to extend between connectors 500 and510. In the structure of FIG. 3, two L-shaped connectors 600, 610 areprovided having horizontally extending pins 14. The horizontal plates ofeach connector 600, 610 have a series of horizontal bolt holes (notshown) configured to accept the vertical bolts 612. There are no boltholes on the vertical plates of connectors 600, 610 in this embodiment.

A third connector 700 comprises a horizontal plate with upwardly andvertically extending pins 14 each of which engages with a correspondingflange 16 of the upper column 100. Bolt holes are disposed so as for thefourth connector of FIG. 2A, the position of bolt holes shown as forFIG. 2B.

A fourth connector 800 comprises a horizontal plate from which pins 14extend vertically and downwardly, each of which engages a flange of thelower column. The fourth connector has bolt holes positioned so as toalign with the bolt holes of the first 600, second 610 and thirdconnector 700. In this embodiment, the lower column (with connector) isplaced firstly, and the upper column 100 (with connectors 600 and 610attached) then lowered downwardly thereon. The two L-shaped connectors600, 610 (each with a collocated beam 300, 400 attached) are thenpositioned so as to sit on the connectors 700, 800 with the horizontalplates of all four connectors being bolted together.

The plan view of the structure of FIG. 3 will be the same as for FIG.2B.

In this arrangement, each of the horizontal beams 300, 400 may beconsidered a half-beam upon which flooring (not shown) may be laid.

FIG. 4 shows an alternative embodiment useful at a corner of a building.Show in plan view is the upper surface of a first connector plate 900having a central region 905 extending from which is a first extendedregion 910 and a second extended region 920. The extended regions 910and 920 support first L-shaped connector 930 and a second L-shapedconnector 940 which are disposed on top of the first connector 900. Theextended region 910 and L-shaped connector 930 have aligned bolt holesto facilitate fastening to each other with vertical bolts 905. Theextended region 920 and L-shaped connector 940 have aligned bolt holesto facilitate fastening to each other with vertical bolts 905

Extending downwardly and vertically from the central region 905 is aseries of pins (not shown) each of which engages with a borehole in aflange, each flange being a component of a column.

Each L-shaped connector 930 and 940 has a series of pins 14 extendingfrom its vertical component, each of the pins engaging with a flange 16,the flanges being collocated into beams 950 and 960.

Extending upwardly and vertically from the central region 905 of thefirst connector 900 is an L-shaped plate 970 which is welded to theupper surface of first connector 900. Bolts 908 are provided to fastentogether the horizontal components of the L-shaped plate 970 withL-shaped connectors 930 and 940.

The arrangement of connectors 930, 940 and plate 970 leaves an L-shapedspace allowing for the lowering of a box-shaped vertical flange 980downwardly and onto the central region 905 of the connector 900. Thebox-shaped flange 980 originates from a column disposed above (notshown) and extends from a connector plate having pins extending upwardlyso as to collocate a number of flanges to form the column.

The box-shaped vertical flange 980 has bolt holes which align with boltholes of the vertical components of the L-shaped connectors 930, 940 andthe L-shaped plate 970. Bolts are inserted through these bolt holes as afinal step so as to secure the corner structure.

Thus, it will be apparent that by this arrangement the beams 950 and 960form a right angle at to the column at a corner of a building.

Reference is made to FIG. 5A showing the use of the corner structuresshown in FIG. 4 in the context of an entire building floor. Each of thecorner structures 1000, 1100, 1200, 1300 has extending therefrom twobeams 1400 at right angles. The beams have inside ledges 1410 allowingfor the disposition of a series of flooring joists 1500 thereon. In thisembodiment, the beams 1400 are constructed from true rounds, chamferedand stacked four flanges high, and then abutting the four-stackedflanges are two-stacked flanges as is shown in FIG. 5C. The ledge 1410is shown more clearly in FIG. 5C. It is not necessary for the ledge 1410to be continuous as shown in the drawings. Instead, for example, asimple block-like support may be affixed to the beam 1400 only wherenecessary to support a joist 1500. Neither beam 1400D nor 1400B has anyledge in this embodiment.

Each joist 1500 is comprised of a stack of three, four or five chamferedtimber flanges, which may be laminated together by any method deemedsuitable by the skilled person. In addition or alternatively, theflanges may be collocated using a connector of the present invention,being generally a plate having outwardly extending pins inserting into aborehole of each flange. The joists may be comprised of peeler coreswhich are collocated with a connector comprising a plate having pinsextending therefrom and into an axial borehole in each flange asgenerally taught herein.

In the building structure of FIG. 5A the beams 1400D and 1400B arepre-fitted to their respective supporting corner columns. On site, thebeams 1400A and 1400C are assembled with joists 1500. Each joist 1500(being timber flanges collocated by a connector of the presentinvention) may be bracketed or cleated or otherwise attached to the beam1400A and 1400C. Once assembled, the combination of beams and joists(forming a grid-like building module) is lowered onto and secured to thecolumns upon which each beam rests. Building structures that can beassembled on site at least to some extent, are advantageous in thattransport of the unassembled components is typically easier and lessexpensive than for assembled modules. Alternatively, structurescomprising all four beams 1400A, 1400B, 1400C, 1400D and all joists 1500may be fabricated on site as a module and lowered onto the columns atthe corners 1000, 1100, 1200, 1300. As an alternative to on-sitefabrication, such building modules may be fabricated in an off-sitefactory and transported fully assemble to the building site.

Further advantage is provided where a building structure does notrequire any gluing to be performed on site. In some embodiments, flangesare collocated without the need for gluing, in which case a pressure fitis typically formed between a pin of a connector and an axial bore holeof a timber flange. The avoidance of glue saves a considerable amount oftime in construction given there is no need to (i) apply glue and (ii)allow sufficient time for the glue to cure before moving assembledmodules.

Reference is now made to FIG. 5B which is directed to an alternativebuilding structure to that shown in FIG. 5A. It will be noted that thejoists 1500 are about one-half the length of those shown in FIG. 5A andaccordingly requires a median beam 1510 disposed one-half way betweenthe beams 1400A and 1400C.

The median beam 1510 rests on the ledges 1410B and 1410D and spansacross beams 1400B and 1400D. Median beam 1510 functions so as tosupport and transfer load from the joists 1500, and then to beams 1400Dand 1400B. In turn, load force is transferred from 1400D and 1400B tothe columns at each corner 1000, 1100, 1200, 1300. The median beam 1510may be comprised of chamfered timer flanges collocated using a connectorof the present invention. In the embodiment shown in FIG. 5B two sets(1510A and 1510B) of stacked flanges are cross-bolted together withbolts 1515.

Thus, in the construction of the 6000 mm×4800 mm module shown in FIG.5B, two half-modules each of 6000 mm×2400 mm may be fabricated on-siteor prefabricated in a factory. The first half-module comprises beams1400A and 1510A with half-joists 1500 extending therebetween, and thesecond half-module comprises beams 1400C and 1510B with half-joists 1500extending therebetween. The half-joists 1500 may be end grain pinnedinto the median beam 1510.

The two half-modules may be fastened together with bolts 1515 eitherbefore or after being lowered into position on beams at corners 1000,1100, 1200, 1300. A supplementary beam (not shown) may be sandwichedbetween 1510A and 1510B so as to provide increased strength if required.

With regard to the embodiment of FIG. 5B it will be noted that a ledge1410B is provided along beam 1400B, and a further ledge 1410D providedalong beam 1400D, these ledges providing support for the median beam1510.

Reference is made to FIG. 5C which shows an exemplary arrangement of ajoist 1500 resting on a ledge 1410. A cross-pin 1530 is inserted into abore hole drilled through the stacked flanges.

As will be appreciated, this arrangement is exemplary only, with manyother variations being utile.

Where it is required to end join any beam or joist in order to span arequired distance across a building, an arrangement as shown in FIG. 5Cmay be used whereby two connector plates 1560, 1570 having pinsextending therefrom to collocate the individual chamfered flanges 16 areend fastened with bolts 1575 so as to form a structurally integral joistor beam. The plates 1560, 1570 may be configured so as to sit on orattach to other building components as required. This is a relativelysimple form of the connector of the present invention, being a singleplate with a series of pins extending therefrom.

The building modules shown in FIGS. 5A and 5B can be fabricated onsiteor offsite as required and lifted into position, with sequential floorsbeing placed on top of the other so as to create a multistorey building.

Any of the beams or joists in a building structure of the presentinvention may be fabricated according to WO/2015/176125, WO/2015/031957,WO/2010/057243 WO/2009/094696, WO/2016/086275, Australian provisionalpatent application 2016902472 (filed 23 Jun. 2016), the contents ofwhich are herein incorporated into the specification by reference.

The structure of FIG. 5A or 5B may be considered modular in nature, andtherefore amenable to be substantially repeated and extended in alldirections (x, y) as required according to the area of the buildingfootprint. For example, beam 1400A may have an identical beam bolted toits rear face (i.e. the face opposed to the ledged face), with theidentical beam having a ledge extending in the opposite direction to theledge 1410A. This arrangement provides a beam having an invertedT-shaped cross-section. The ledge on the identical beam in turn supportsone end of a further series of joists identical to those marked 1500.Typically, the beam 1400A and its abutting identical beam will be boltedtogether at a number or points along their lengths.

In this description of FIGS. 5A and 5B, all columns, beams and joistsare comprised of collocated timber flanges. In some embodiments, priorart timbers (such as square sawn lumber, any laminated timber orotherwise engineered timber) may be used for at least some of thecolumns, beams or joists. In some circumstances, the expense of priorart timbers may be justified for reasons of strength, ease of use orlocal building regulations.

In some building applications, it may be necessary to form a joinbetween four beams, with upper and lower beams being disposed at theintersection of the beams. A suitable arrangement of connectors is shownin FIG. 6. The arrangement comprises a cruciform plate 2000, each of thefour arms of the plate 2000 being to support a beam formed fromcollocated chamfered timber flanges, of the type marked 2010. Twoupwardly extending parallel plates 2020, 2030 are welded onto the centreportion of the plate 2000. The space between the plates 2020, 2030 isdimensioned so as to accept the vertical plate 524. The plates 2020 and2030 are used so as to afford greater overall strength as compared withthe arrangement shown in FIG. 2A whereby the connector plates 500 and510 are bolted directly to the vertical plate 524. As such the plates2020 and 2030 are optional.

The vertical plate 524 is joined to a horizontal plate (not shown) andcollocated upper column flanges (not shown) as drawn in FIG. 2A (seecomponents 524, 520, 522, 100).

In this arrangement, there are four beams (only one of which is shown as2010 for clarity) each of which extend outwardly from the centre at the12 o'clock, 3 o'clock, 6 o'clock and 9 o'clock position. The beam shownas 2010 is formed from flanges collocated using the L-shaped connector2040. The connector 2040 contacts the plate 2030 upon assembly. A mirrorimage of the connector 2040 and beam 2010 contacts the plate 2020 uponassembly. The two beam which extend at 90 degrees to beam 2010 aresimilarly collocated with an L-shaped connector, with the verticalcomponents of the connectors abutting the edges of plates 2020 and 2030,with the horizontal components of the L-shaped connectors boltingdownwardly to the plate 2000 (bolt holes not shown). A lower beam (notshown) is formed of flanges collocated by a connector similar to thatmarked 530 in FIG. 2A.

As will be appreciated, an arrangement suitable for joining three beamsin a T-formation may be provided by modifying the cruciform plate 2000to exhibit a T-shape.

Reference is now made to FIG. 7 which shows an H-shaped connector 2100having two parallel plates 2110 and 2120. The bottom edge of each plate2110 and/or 2120 may be welded to a lower connector plate. Each ofplates 2110 and 2120 has a series of bolt holes 2130 allowing bolting ofL-shapes connector plates (such as that shown as 10 in FIG. 1A) to theoutwardly directed faces of plates 2110 and 2120. Bolts holes are alsoformed in the cross-plate 2140 allow for the attachment of furtherconnector plates. The cross-plate 2140 may be not be required in someembodiments, in which case the connector comprises simply one of plates2110 and 2120.

In the description provided herein, numerous specific details are setforth. However, it is understood that embodiments of the invention maybe practiced without these specific details. In other instances,well-known methods, structures and techniques have not been shown indetail in order not to obscure an understanding of this description.

In the following claims, any of the claimed embodiments can be used inany combination.

1. A connector for collocating a group of timber flanges, the connectorcomprising a main region, the main region having extending therefrom aplurality of engaging members each of which is configured to engage witha timber flange.
 2. The connector of claim 1 wherein the main regioncomprises means for fastening the connector to a substantially similaror identical second connector, or to a building structure.
 3. (canceled)4. The connector of claim 1 wherein the main region comprises a firstsubstantially planar region and a second substantially planar region,the first and second planar regions forming an angle of about 90degrees, the first planar region comprising means for connecting theconnector to a substantially similar or identical second connector, andthe second planar region comprising means for connecting the connectorto a building structure.
 5. The connector of claim 4 wherein the meansfor connecting the connector to a substantially similar or identicalsecond connector or the means for connecting the connector to a buildingstructure is an aperture configured to accept a fastener.
 6. Theconnector of claim 1 wherein the plurality of engaging members aredisposed in an ordered array with reference to each other.
 7. Theconnector of claim 1 wherein the main region consists of, or comprises,a plate and each of the plurality of engaging members is a dowel or pinextending from the plate.
 8. The connector of claim 1 configured to endjoin a first group of timber flanges to a second group of timberflanges, the connector comprising a main region, the main region havingextending therefrom a plurality of engaging members each of which isconfigured to engage with an axial bore of timber flange, the pluralityof engaging members comprising a first group and a second group, whereinthe first group extends in a first direction and the second groupextends in a second direction.
 9. The connector of claim 8 wherein themain region comprises opposing first and second substantially planarfaces, wherein the first group of the engaging members extendsubstantially orthogonal to the first planar face and the second groupof engaging members extend substantially orthogonal to the second planarface.
 10. A building component comprising: (i) a first connectorcomprising a main region, the main region having extending therefrom aplurality of engaging members each of which is configured to engage witha timber flange, and (ii) a plurality of timber flanges, each of thetimber flanges having an axial bore into which is received one of theengaging members.
 11. (canceled)
 12. (canceled)
 13. The buildingcomponent of claim 10 wherein each of the plurality of timber flanges isa true round or a peeler core.
 14. The building component of claim 10wherein a longitudinal surface is formed by removing a longitudinalsegment of each of the timber flanges so as to provide a substantiallyplanar surface, and wherein a substantially planar surface of each ofthe plurality of timber flanges contacts a substantially planar surfaceof at least one other timber flange.
 15. (canceled)
 16. The buildingcomponent of claim 14 wherein two contacting timber flanges are securedtogether with a fastener extending at an angle to the long axes of thetimber flanges.
 17. The building component of claim 10, furthercomprising: (iii) a second connector comprising a main region, the mainregion having extending therefrom a plurality of engaging members eachof which is configured to engage with a timber flange, and wherein theplurality of timber flanges comprises a first group of timber flangescollocated by the first connector and a second group of timber flangescollocated by the second connector, the first and second groups oftimber flanges oriented end-to-end, the first and second connectorsbeing fastened together so as to form a structurally integral unit. 18.The building component of claim 17 comprising a structural column,wherein the first and second connectors are disposed on, and fixed to,the upper face of the column, or a plate engaged with the top of thecolumn, and the first connector is fastened to the second connector. 19.The building component of claim 17 comprising a third connectorcomprising a main region, the main region having extending therefrom aplurality of engaging members each of which is configured to engage witha timber flange, the third member further comprising a support memberextending from the main region in a direction generally away from theengaging members, the support member of the third connector interposedbetween the first and second connector, and the first connector isconnected to the second connector.
 20. The building component of claim19 comprising a third group of timber flanges collocated by the thirdconnector.
 21. The building component of claim 19 comprising a fourthconnector comprising a main region, the main region having extendingtherefrom a plurality of engaging members each of which is configured toengage with a timber flange.
 22. The building component of claim 21comprising a fourth group of timber flanges collocated by the fourthconnector and the fourth connector is fastened to the first and secondconnectors.
 23. (canceled)
 24. The building component of claim 22wherein the first and second group of timber flanges are configured asjoists, the third group of timber flanges is configured as column of a(n+1) storey of a building, and the fourth group of timber flanges isconfigured as column of a (n) storey of the building.
 25. A method ofconstructing a building component, the method comprising use of abuilding component comprising: (i) a connector comprising a main regionhaving extending therefrom a plurality of engaging members and (ii) aplurality of timber flanges each of which comprises an axial boreconfigured to receive one of the engaging members, wherein the methodcomprises engaging one of the plurality of axial bores with one of theplurality of engaging members.